Perforated functional textile structures

ABSTRACT

The invention provides a functional stretch laminate composite puckered fabric which is robust, laundry-durable and adaptable for securing about any three dimensional body, and a method for forming such puckered fabric. The functional stretch laminate fabric is provided with at least one functional element which can conduct electricity, conduct light, provide electromagnetic fields or provide shielding from electromagnetic fields. In addition, at least one via is provided in the functional stretch laminate allowing the functional element to extend or loop outwardly from the at least one via when the laminate is in a relaxed or unstretched state. Generally, the functional stretch laminate fabric is sufficiently robust for incorporation into garments and for applications in so-called wearable electronics.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. Ser. No. 11/570,308 filed onDec. 8, 2006, now U.S. Pat. No. 7,781,051, filed as a national stageentry of PCT/lB2005/001681 on Jun. 15, 2005, which claimed priority fromU.S. Provisional Application No. 60/581,048, filed Jun. 18, 2004.

FIELD OF THE INVENTION

The present invention relates to flexible and elastic textilestructures, adapted for securing about a three dimensional object,having the ability to, for example, conduct electricity, conduct light,and to provide or influence electromagnetic fields.

BACKGROUND OF THE INVENTION

Different types of flexible and elastic textile structures having anability to conduct electricity or to influence electromagnetic fieldshave been disclosed for certain medical and physiological monitoringapplications. For example, U.S. Pat. No. 6,341,504 to Cynthia L. (stook(assigned to VivoMetrics®, Inc., Ventura, Calif., USA) discloses acomposite elastic fabric construction for apparel applications of thetype used in physiological monitoring wherein the stretching andstretch-recovery of the composite elastic fabric changes the inductanceof an electrically conductive curved wire affixed to or incorporated inthe composite fabric. VivoMetrics® Inc. is the maker the Lifeshirt™,which incorporates the flexible electrically conductive textilestructure of Istook and is used primarily for physiological monitoringand other ambulatory wearer measurement capabilities. In general, theIstook structure requires that one or more conducting wires be stitchedto the face of an elastic band structure in order to form the curvedwire geometry for the intended application.

PCT publication WO 2003/087451A2 to Vikram Sharma (“Sharma”) discloses atubular knit fabric system comprising an electrically insulating yarn, astretch yarn, and a “functional” yarn knitted together to form a tubularknit fabric. In Sharma, the functional yarn is electrically conductive,having a resistance of 0.01 ohm/meter to 5000 ohm/meter. The“functional” yarn is embedded within the tubular knit in a continuousspiral that extends the length of a sleeve formed from the tubular knit.Body portions, such as limbs, are surrounded by a portion of the tubularfabric to measure physiological signs. In addition, these tubular knitfabrics disclosed by Sharma are adaptable for use in a narrow elasticband configuration in which the functional yarns serve as parallelconductors for electrical signals. A disadvantage of Sharma's narrowelastic band structures is that the functional yarns or wires must beknitted simultaneously into the structure with all other components.

In addition to electrically conducting elements, optical fibers forlight conduction have been disclosed for incorporation into garments.For example, U.S. Pat. No. 6,315,009 to Sundaresan Jayaraman et al.(assigned to Georgia Tech Research Corp.) (“Jayaraman”) discloses afull-fashioned continuously woven garment consisting of a comfortcomponent and sensing component of the base fabric. According toJayaraman, the sensing component can be an electrically conductivecomponent or a penetration sensing component. For example, thepenetration sensing component can be an optical conductor such asplastic optical fiber. A disadvantage of the Jayaraman construction isthe need to simultaneously weave directly into the tubular fabric orgarment the elastic yarn and the functional component(s), e.g. plasticoptical fiber.

The above references incorporate functional components, such aselectrical conductors, through the use of fabric structures of a wovenor knitted type. Such functional components can have poor compatibilitywith conventional textiles. Moreover, such functional componentsgenerally cause difficulties in conventional fabric forming processes(e.g. weaving, knitting, seamless knitting). For example, wires, smallcables, and plastic optical fibers often match poorly with typicaltextile fibers because of their fragility, elastic modulus,extensibility, and tensile strength. In particular, such disadvantagesare notable where elastic recovery and flexibility from the structure orgarment is desired and where the ability to wash or launder a garment isdesired. Thus, flexible and elastic textile structures are needed thatcan overcome one or more deficiencies of the prior art.

The art continues to seek structures with elements able to conductelectricity, conduct light, or influence electromagnetic fields for usein certain medical and/or physiological monitoring applications, as wellas industrial and interconnect applications, wherein the structures donot have at least one of the deficiencies mentioned above. An ability toprovide a launderable garment that incorporates functional elements intoflexible textile-like structures without the need to knit or weave suchelements would be highly desirable.

SUMMARY OF THE INVENTION

The present invention relates to a perforated functional stretchlaminate with a substantially puckered appearance. The perforatedfunctional stretch laminate includes: first and second outer layers of afabric, paper or film; at least one stretch and recovery element and atleast one functional element co-extending with the stretch and recoveryelement; and an adhesive composition for bonding the stretch andrecovery element and the functional element between the outer layers;wherein the substantially puckered appearance results when the stretchand recovery element is in a relaxed or unstretched state, and wherein aportion of the at least one functional element extends or loopsoutwardly from at least one hole or via provided in the functionalstretch laminate. The functional stretch laminate of the invention canbe conductive and can, for example, conduct electricity, conduct light,or provide an electromagnetic field.

The present invention further relates to a method for preparing aperforated functional stretch laminate with a substantially puckeredappearance. The method includes: providing a length of a first piece ofinextensible material having a first surface and a second surface;extending and fixing at least one length of a stretch and recoveryelement to at least 50% of its undeformed recoverable extension limit,and extending and fixing at least one length of a functional elementcoextensively with the stretch and recovery element, and furthersecuring the extended lengths of the stretch and recovery element andthe functional element to the first surface of said first piece ofinextensible material along a substantial portion of the fixed lengththereof; providing a second piece of inextensible material having afirst surface and second surface, and securing said second piece ofinextensible material either to the stretch and recovery element or tothe first surface of said first piece of inextensible material along asubstantial portion of the length thereof coextending with said stretchand recovery element to form the functional stretch laminate; andrelaxing the extended length of said stretch and recovery elementsubstantially and allowing the functional stretch laminate to pucker,such that a portion of the at least one functional element extends orloops outwardly from at least one hole or via provided in the functionalstretch laminate.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in the following detaileddescription with reference to the following drawings:

FIG. 1 is a schematic representation in side elevation of an apparatussuitable for making a functional stretch laminate of the invention;

FIG. 2 is a schematic representation in top plan view of a portion of anapparatus for making a functional stretch laminate of the invention;

FIGS. 3A and 3B are schematic representations in cross-section of afunctional stretch laminate of the invention, illustrating a sandwich ofstretch and recovery elements and functional elements between twofabrics or sheets of other inextensible material;

FIGS. 4A and 4B are schematic representations of an edge sectional viewof a composite fabric used in a functional stretch laminate of theinvention; in FIG. 4A the composite fabric is under an elongatingtension, and in FIG. 4B the composite fabric is relaxed and under noelongating tension;

FIGS. 5A-5D are top plan views of perforation patterns that may be usedto form perforations in an outer sheet of the composite stretch laminateto expose functional elements;

FIGS. 5E and 5F are perspective views of functional stretch laminateswherein portions of the functional elements loop out of one outer layerof the laminate; in FIG. 5E two loops are shown extending through anelongated slot-shaped perforation and in FIG. 5F four loops are showneach extending through an individual perforation hole;

FIGS. 6A and 6B are schematic representations of an edge sectional viewof a functional stretch laminate of the invention; in FIG. 6A thefunctional stretch laminate is under an elongating tension, and in FIG.6B the functional stretch laminate is relaxed an under no elongatingtension;

FIG. 7A is a perspective view of a functional stretch laminate of theinvention in which z-folds are formed at each end to stabilize thefunctional element within the laminate; and

FIG. 7B is a cross-sectional view in side elevation of a clampingengagement to provide one possible electrical connection means at thez-fold formed at one end of the functional stretch laminate of FIG. 7A.

DETAILED DESCRIPTION OF THE INVENTION

The invention includes a functional stretch laminate that may be acomposite fabric with a substantially flat surface appearance, which isalso able to take on a substantially puckered appearance. The stretchlaminate can be conductive, robust, laundry-durable, and adapted forsecuring about any three dimensional body.

The functional stretch laminate of the invention generally includes:

(a) first and second outer layers of nonwoven, knitted, or woven fabric,paper or film, wherein each layer has an inside (or first) surface andan outside (or second) surface with respect to the composite fabric;

(b) at least one threadline of a stretch and recovery element, such as afiber having elastomeric properties sandwiched between the outer layers;

(c) at least one functional element also sandwiched between the outerlayers;

(d) an adhesive composition for bonding the first and second outerlayers, or for bonding the first and second outer layers to the stretchand recovery element or for bonding the first and second outer layers tothe functional element; and

(e) at least one hole or via, which allows at least one functionalelement to extend or loop outwardly from the functional stretch laminatewhen the laminate is in a relaxed or unstretched state.

The two outer layers of nonwoven, knitted, or woven fabric, paper orfilm can, in one embodiment, be of substantially equal width.

The elastomeric fiber can, in one embodiment, be at least 400 decitex,wherein the number of threadlines and fiber decitex are in arelationship such that the retractive force of the stretchable fabric isat least 0.22 lb/inch (38.9 g/cm).

In addition, the adhesive composition can, in one embodiment, comprisebetween about 8 and 70% of the laminate by weight, and although appliedto only partially cover the inside surface of at least one outer layer,such adhesive may penetrate to the outside of each outer layer to anextent less than about 10%, based on the surface area of each outerlayer.

Further, the functional element can be substantially parallel orcoextensive with the stretch and recovery element.

The invention further provides a method for making a functional stretchlaminate with a puckered appearance which includes the steps of:

providing a length of a first piece of inextensible material having afirst surface and a second surface;

extending and fixing at least one length of a stretch and recoveryelement to at least 50% of its undeformed recoverable extension limit,and

extending and fixing at least one length of a functional elementcoextensively with the stretch and recovery element;

securing the extended lengths of the stretch and recovery element andthe functional element to the first surface of said first piece ofinextensible material along a substantial portion of the fixed lengththereof;

providing a second piece of inextensible material having a first surfaceand second surface, and securing said second piece of inextensiblematerial to the stretch and recovery element, the functional element, orthe first surface of said first piece of inextensible material along asubstantial portion of the length thereof coextending with said stretchand recovery element to form the functional stretch laminate; and

relaxing the extended length of said stretch and recovery elementsubstantially and allowing the functional stretch laminate to puckersuch that at least one functional element extends or loops outwardlyfrom at least one via provided in the functional stretch laminate. Thismethod may further comprise the step of attaching at least one connectorto the functional stretch laminate, wherein said connector is adaptablefor connecting the at least one functional element in the laminate to asource selected from the group consisting of electricity and radiation.Radiation may be photonic radiation selected from those wavelengths oflight employed in fiber optic networks for data communication.

In one embodiment of the inventive method, the outer layers aresubstantially planarized and secured in place when the at least onestretch and recovery element and the at least one functional element aresecured to such layers. As used herein, the term “planarizing” means tobring a portion of a fabric, a web, or a film into a substantiallyplanar and unwrinkled configuration without puckers.

As used herein, suitable “substantially inextensible materials” includenonwoven fabrics, woven fabrics, knit fabrics, papers, oriented andunoriented films, including variants of the foregoing with metalliccoatings. These woven, nonwoven, and knit fabrics may comprise staple orcontinuous fibers, including those fibers from polyolefins, polyesters,polyamides, and polyperfluorinated olefins. Suitable films may comprisepolymers, including polyester, polyolefins, polyperfluorinated olefins,and polyamides. The fabrics or films of the outer layers of thefunctional stretch laminate can include any of the above-mentionedsubstantially inextensible materials.

As used herein, suitable “stretch and recovery elements” include atleast spandex or elastane yarns, films, or coatings (for example,LYCRA®spandex). Suitable stretch and recovery elements can furtherinclude materials such as a polyester bicomponent fiber, for example,Type 400 brand poly(ethylene terephthalate)//poly(trimethyleneterephthalate) bicomponent fiber, commercially available from Invista S.à r. l. (“T400”). Stretch and recovery elements can also includematerials that provide both stretch and recovery and functionalproperties, such as the conductive stretchable composite yarns disclosedin PCT publication WO 2004/097089 A1, the entire disclosure of which isincorporated herein by reference (hereinafter referred to as“electrically or optically functional composite yarns that comprise anelastic member surrounded by at least one functional coveringfilament”).

Suitable stretch and recovery elements can have a breaking elongation ofover 200%, such as over 400%. In addition, such materials can recoverimmediately to their original length when tension is relaxed.

As used herein, the term “functional” means elements or materials thatexhibit electrical, optical, magnetic, mechanical, chemical, and/orthermal energy properties.

Examples of “functional materials” include, but are not limited to,materials that present: electrical function (e.g., electricalconductivity, heating, piezoelectric, electrostrictive, electrochromicactivity); optical function (e.g., photonic crystal fibers,photoluminesce, luminescence, light transmission, reflection); magneticfunction (e.g., magnetostrictive activity); thermoresponsive function(e.g., shape memory polymers or alloys); and sensorial function (e.g.,chemical, bio, capacitive). Such functional materials can be included infunctional elements used in embodiments of the present invention.

As used herein, suitable “functional elements” include: metallic wiresof the insulated or noninsulated variety, having one or more conductors,such as litz wire, tinsel wire, or stranded conductors for highfrequency use; single stranded metallic wires having circular ornoncircular cross-sections, such as, ribbon wire; metallic coatedpolymeric wires and films, such as, Xstatic® yarns and metallized MYLAR®(from DuPont-Teijin Films, Hopewell, Va., USA); inherently conductivepolymer fibers such as those from polypyrrole; plastic optical fiberfrom polymethyl methacrylate, such as, CROFON®; and silica glass opticalfibers of the multi-mode or single-mode variety suitable for fiber opticnetworks based on Ethernet, Fiber Channel, FDDI, ATM and Token Ringprotocols. Suitable functional elements also include electricallyconductive composite yarns that comprise an elastic member surrounded byat least one conductive covering filament, as well as the elastomericcompositions disclosed in U.S. Provisional application Ser. No.60/562,622, filed Apr. 15, 2004, the entire disclosure of which isincorporated herein by reference (hereinafter referred to as“electrically conductive elastomeric compositions that exhibit variableresistance”).

As used herein, the term “adapted for securing about any threedimensional body” means the functional stretch laminate is flexible andelastic allowing conformance to any shape. Particularly, where thefunctional stretch laminate is a garment or a component of a garment orother wearable placed on at least a portion of a body, the laminate isat least as adaptable as the garment or wearable in conforming to thethree dimensional shape of the body. Inherent in the adaptableconformance of the laminate to any three dimensional body is arobustness of the laminate structure to maintain the performance of thelaminate's functional element in the presence of any motion of the threedimensional shape to which the laminate is conforming.

As used herein, the term “laundry durable” means the functional stretchlaminate is at least washable. Particularly, where the functionalstretch laminate is a component of a washable garment or other washablewearable placed on the body, the laminate structure maintains theperformance of the laminate's functional element after multiple washingor laundry cycles. For example, maintaining functional elementperformance after at least one wash cycle would be “laundry durable.”

As used herein, the term “conductive” means at least a portion of thestretch laminate conducts electricity, conducts light, or is able inprovide an electromagnetic field, or is able to provide shielding fromelectromagnetic fields.

As used herein, the term “substantially parallel or coextensive” meansthat the stretch and recovery element(s) and functional element(s)extend lengthwise in the same direction of the functional stretchlaminate (also known as the “machine direction”) without contacting anadjacent stretch and recovery element or functional element. Suchsubstantially parallel or coextensive elements can be, in at least oneembodiment, substantially equidistant from the other stretch andrecovery elements(s) and/or functional elements(s) along their length inthe direction perpendicular to the direction in which they extend. Forexample, when a stretch and recovery element extends in the machinedirection of the functional stretch laminate, then a substantiallyparallel or coextensive functional element also extends in the machinedirection, and both elements are substantially equidistant from eachother in the direction perpendicular to the machine direction at pointsalong their length. The term “substantially parallel or coextensive”also includes those situations where both the stretch and recoveryelement and functional element are uniformly tensioned in the samedirection (such as when both are uniformly tensioned in the machinedirection).

The functional stretch laminate of the invention, in one embodiment, isa composite having varying amounts of puckering, and includes two outerlayers of nonwoven fabric and an inner “layer” comprised of at least onefunctional element and two or more substantially parallel or coextensiveelastomeric fibers (stretch and recovery elements) of substantiallyequal decitex, which are capable of complete recovery from extensions asgreat as 300%. The elastomeric fibers are substantially relaxed in theabsence of externally applied forces. In addition, in a furtherembodiment, the elastomeric fibers may be equally spaced from each otherin the direction perpendicular to their length.

Nonwoven fabrics suitable for making functional stretch laminates of theinvention can have a basis weight ranging from about 10 to about 100grams/(meter)², such as from about 10 to about 30 grams/(meter)². Manytypes of nonwoven fabrics are suitable for use in embodiments of thisinvention. Representative examples include nonwovens composed ofthermally bonded, spunbonded, and hydroentangled fibers. For example,they may be composed of synthetic polymeric fibers such as polyolefin,polyester, and polyamide fibers.

The functional stretch laminate of the invention comprises a middle“layer” of two or more elastomeric fibers and at least one functionalelement sandwiched between the outer layers of inextensible material,such as nonwoven fabrics or a films. This middle “layer” may includeelastomeric fibers of at least one threadline, for example, 3.2threadlines/cm of width wherein each threadline is at least 400 decitex.The number of threadlines per cm may, for example, be up to about 6.3.The combination of these two parameters (threadlines and dcitex) may,for example, be chosen to provide a minimum retractive force of about38.9 (grams of force)/cm, as measured in the finished product when it isstretched at 150% of its original length.

The elastomeric fibers can be substantially parallel to the edges of theouter layer fabrics or films. One example of a suitable elastomericfiber is Lycra® spandex fiber (a registered trademark INVISTA S.à r.l).

The functional element(s) in this middle “layer” may, in one embodiment,be a metallic wire of the insulated or uninsulated variety. For example,single conductor wire may be used. The use of more conductors per wire,such as litz wire or stranded conductors, is suitable for high frequencyelectrical use. A single stranded metallic wire having a circular ornoncircular cross-section, such as ribbon wire, is suitable for highcurrents or where a more rigid puckered laminate is preferred. Inaddition, flat metallic wires, may be used such as the flat copper wire(insulated or non-insulated) from REA Magnet Wire Co., Fort Wayne, Ind.Certain metallic coated polymeric fibers may also be used, such as,Xstatic® yarns, which are silver plated textile nylon filamentsavailable from Laird Sauquoit Technologies, Inc. (300 Palm Street,Scranton, Pa., 18505) under the trademark X-static® yarn. One suitableform of X-static® yarn is based upon a 70 denier (77 dtex), 34 filamenttextured nylon available from INVISTA S. à r. l., Wilmington, Del. asproduct ID 70-XS-34×2 TEX 5Z electroplated with electrically conductivesilver. Another suitable conductive yarn is a metal coated KEVLAR® yarnknown as ARAGON® from E. I. DuPont de Nemours, Inc., Wilmington, Del.Also useful in embodiments of the invention are members of the class ofinherently conductive polymer fibers, such as those from polypyrrole. Inaddition, the plastic optical fiber (POF) from polymethyl methacrylatepolymers may be used. Where a functional element for guiding light isdesired, a POF, such as CROFON® may be used. Useful POF may, forexample, be of the step-index type (SI-POF) or the graded index type(GRIN-POF) for higher speed optical communications. The class of silicaglass optical fibers of either the multi-mode or single-mode varietyalso comprise a useful class of functional elements suitable for fiberoptic networks based on Ethernet, Fiber Channel, FDDI, ATM, and TokenRing protocols.

In addition, the functional element can comprise a conductive yarn, suchas of Xstatic® yarn or fiber twisted together with wire, for example,copper wire. The functional element can further comprise electricallyconductive composite yarns that comprise an elastic member surrounded byat least one conductive covering filament or electrically conductiveelastomeric compositions that exhibit variable resistance twistedtogether with Spandex and/or Xstatic® yarn.

The layers of the functional stretch laminate are bonded together by anadhesive composition. Each element in the composite should be bonded toat least one other element of the composite. For example, an adhesivemay be applied to the stretch and recovery element and the functionalelement, and in turn those elements adhered to inner surfaces of theouter layers. As another example, an adhesive may be applied to an innersurface of one of the outer layers. The adhesive composition can, forexample, constitute from about 8% to 70% of the weight of the compositefabric. Adhesive content in the functional stretch laminate above theselevels may, in certain circumstances, be disadvantageous, as the fabricmay bond to itself. Suitable adhesive compositions can, for example, behot melt adhesives, such as styrene-based block copolymers, includingstyrene/isoprene and styrene/butadiene block copolymers. Bonding byother methods may be possible, such as flame lamination and laser orultrasonic welding, if such techniques can be carried out withoutharming the functional element and the stretch and recovery element.

The functional stretch laminate can, for example, be prepared in amethod whereby uniformly tensioned elastomeric filaments are spaced atsubstantially equal distances apart and are of substantially equaldecitex, for example, no less than 400 decitex per filament, such asabout 2,200 dtex threadlines fed in together. These elastomericfilaments are placed between two layers of fabric, such as nonwovenfabric. In one embodiment, at least 3.15 filaments (threadlines) per cmof width are provided. The threadlines can be substantially parallel toeach other and to the edges of the nonwoven fabrics. The three layersare bonded with an adhesive, which can be followed by removing thetension immediately after bonding. This method can produce a puckeredfabric having a substantially uniform flat surface appearance whichresults from small substantially uniform puckers.

The number of functional elements per inch of width of laminate materialis not limited and can, for example, range from 1 to 20, such as from 5to 10.

The apparatus schematically represented in side elevation in FIG. 1 maybe used in the process of making functional stretch laminates fallingwithin the scope of the present invention. FIG. 1 shows a single supplyroll 2 of functional element 5 (a copper wire, for example) along with asingle supply roll 4 of elastomeric filaments 10. However, a pluralityof supply rolls and functional elements is also contemplated (see, forexample, FIG. 2, which shows supply rolls 2 and 2′ of functional element5 and 5′ and supply rolls 4, 4′, and 4″ of elastomeric filaments 10,10′, and 10″). The elastomeric filaments can be uniformly tensionedbetween roll 15 and nip rolls 50 to provide greater than 50% elongation.A functional element can be uniformly tensioned between roll 15′ and niprolls 50 to provide stability but generally such functional element 5 isnot substantially elongated. In FIG. 1, the single functional element 5and the single elastomeric filament 10 are shown as being side-by-sideand may be separated on any pitch over the roll surface of guide plate25. Where multiple elastomeric fibers and multiple functional elementsare supplied to the process (see FIG. 2 where the machine direction, M,of the process is indicated), it is understood that the guide plate 25(in FIGS. 1 and 2) or an equivalent spacing means can provide theposition and pitch of each elastomeric fiber and functional element. InFIG. 1, a layer of substantially parallel elastomeric fiber 10,stretched not less than 50%, and functional element 5, are shown asbeing placed on top of one of the layers of nonwoven fabric 35 suppliedfrom rolls 33. An adhesive 30, for example, a hot melt adhesive, isapplied onto the elastomeric fiber and functional element and bottomnonwoven layer via conduit 20. The other layer of nonwoven 35′, suppliedfrom rolls 33′, is then placed on top of the adhesive-treatedcombination at roll 40 and the combined structure is bonded by heat andpressure at nip rolls 50 while the elastomeric fibers 10 remain in thestretched condition. Alternatively, the adhesive 30 can be applied tothe elastomeric fiber and functional element prior to their placementbetween layers of nonwoven fabric. When the bonding is completed, theuniform tension is substantially completely released and the compositefabric relaxes to form the desired puckered structure 55. Arrow Dindicates direction of travel of the produced structures 55 away fromthe nip rolls 50.

The hot melt adhesive 30 (see, for example, FIG. 2) can be applied inseveral different ways. In one method, the melted adhesive can bedeposited as a discontinuous web from a spray nozzle (one such nozzle 22is shown at the end of adhesive conduit 20 in FIG. 2), by a processknown as melt blowing. In another method, the melted adhesive can bedeposited as a solid stream from a nozzle that moves in a spiral patternas the web passes, by a process known as spiral spray. A pattern inwhich the adhesive only partially covers the nonwoven layers, such as isproduced by melt-blowing or spiral spray, can result in a uniform, flatsurface appearance of the composite fabric. By “only partially covers”it is meant that the adhesive is present at one part of the nonwoven butabsent at an adjacent part. This can also be accomplished by applying a“dot matrix” pattern.

FIG. 3A and FIG. 3B illustrate functional laminate structures withdifferent functional elements 5 and 5 b. In FIG. 3A, functional element5 is a copper wire. In FIG. 3B, functional element 5 b is ribbon wire.In FIGS. 3A and 3B, elastomeric fibers 10 and nonwoven fabrics 35 and35′ are as described for FIGS. 1 and 2.

The flatness or smoothness of functional stretch laminates of thisinvention can be determined by measuring the change in thickness whenthe functional laminate is stretched from its relaxed state to itsultimate elongation. Generally, the smoother the appearance of thefabric, the smaller the change in thickness on stretching.Alternatively, one can count the number of raised portions, referred toas puckers, per linear cm (inch) of the relaxed functional stretchlaminate fabric (L in FIG. 4B shows a distance between puckers).Starting from a given extended length, as the number of puckersincreases in the relaxed fabric, the amplitude (A in FIG. 4B) of eachpucker decreases. The ratio of these the two values, amplitude (A) andpuckers per linear fixed length (L) (see FIG. 4B), i.e., the ratio ofpercent decrease in thickness to the number of puckers per inch, isreferred to as the “flatness factor.” The functional stretch laminatecan be considered “flat” or “smooth” when the flatness factor is lessthan about 5.

Thickness measurements were made with an Ames Thickness Gage. Thicknesswas measured on the relaxed composite fabric at three different placesand the measurements averaged. The fabric was then stretched to thefullest extent possible. While stretched, the thickness was againmeasured at three different places and the results were averaged. Fromthe difference in thickness values, percent decrease in thickness wascalculated.

The number of puckers per linear fixed length for the functional stretchlaminate was determined by placing a ruler along the length of thefabric parallel to the edge of the fabric. The number of puckers in afixed length were counted. This was repeated at two other locationsacross the width of the fabric. The average of these three measurementswas recorded.

Another useful measurement is the “retractive force” of the functionalstretch laminate. For Examples of the invention described below, theretractive force of the functional stretch laminate was measured asfollows: 7.62 cm (three-inch) long samples of the relaxed stretchablefabric were elongated in an Instron instrument, model 1122, at a rate of15.2 cm/min (6 in/min), The retractive force was recorded when thelength extension reached 50%, that is, when the total length was 150% ofthe original length. The results were recorded as pounds per inch offabric width (the apparatus was calibrated to convert total 0.4536 kg(pounds) to 0.4536 kg (pounds) per 2.54 cm (inch) width for fabrics thatwere wider than one 2.54 cm (inch)).

The functional stretch laminate may be “laundry durable” meaning that itcan undergo at least one laundry cycle without showing evidence ofdelamination of the outer layers (whether polypropylene or polyesterfiber-based nonwovens), which would indicate loss of bonding between thestretch and recovery element(s) and the outer layers. The functionalstretch laminate may also be disposable, for example, when at least oneof the outer layers comprises paper.

The functional stretch laminate fabric may, in certain embodiments, befurther characterized by laundry durability such that it can undergo atleast about 28 laundry cycles without showing evidence of delaminationof the outer layers. To demonstrate such durability, the followinglaundry cycle was used: 30-minute warm wash/warm rinse with 38-41° C.(100-105° F.). water and 50 g of “Tide” detergent in a Sears KenmoreSeries 80 washer, followed by drying on the “normal/permanentpress/medium” setting (up to 96° C. [(205° F.]) in a Sears KenmoreSeries 80 dryer.

The laundry durability of these functional stretch laminate fabricsincorporating spandex as the stretch and recovery element can beprovided by using selected adhesives having a complex viscosity at 120°C. of: (i) at least about 25 pascal seconds (250 poise) when the outerlayers comprise nonwoven fabric that comprises polypropylene fibers; and(ii) at least about 200 pascal seconds (2,000 poise) when the outerlayers comprise nonwoven fabric that comprises polyester fibers.

The absolute value of the complex viscosity is defined as follows:

At a given frequency, ω, and shear stress, σ, the absolute value of thecomplex viscosity, |η*|, is the square root of the sum of the squares ofthe elastic, (G′), and viscous, (G″), moduli divided by the frequency:|η*|=√G′ ² +G″ ²/ω

The softening point of useful adhesives can generally be expected toexceed 90° C. (194° F.) and suitably can generally be expected to exceed110° C. (230° F.).

Examples of adhesives useful in making laundry durable functionalstretch laminate fabrics include those that contain styrene-based blockcopolymers, which may also contain additives, such as tackifying agentsand processing oils. Where the nonwoven fabrics comprise polypropylenefibers, the adhesives can include HL-1486 and HL-1470 (H. B. FullerCompany), and H-2104 and H-2494 (Bostick, Inc., Milwaukee, Wis.). Wherethe nonwoven fabrics comprise polyester and/or polypropylene fibers, theadhesives can include H-2385 (Bostick, Inc., Milwaukee, Wis.) andNS-34-3260, NS-34-3322, and NS-34-5640 (National Starch Company). All ofthe above-named adhesives contain styrene-based block copolymers. Thecomplex viscosity of selected adhesives that are useful in making thelaundry-durable functional stretch laminate fabrics of the invention aredisclosed in EP1 128 952 B1 (granted 20031126 and assigned to E. I.DuPont de Nemours and Co.), the entire disclosure of which isincorporated herein by reference. Notably, it was found that use ofHL-8130 (H. B. Fuller Company), complex viscosity at 120° C. of 15pascal seconds, less than the minimum required 25 pascal seconds, didnot result in laundry-durable stretchable fabrics with either polyester-or polypropylene-based nonwovens.

FIGS. 5A through 5D are top plan views of perforation patterns that maybe used in conjunction with the invention. In FIG. 5A, a series ofeleven round hole perforations 70 a are formed in a regular gridpattern. In FIG. 5B, a series of fourteen round hole perforations 70 bare formed an alternate regular grid pattern. In FIG. 5C, a rectangularslot perforation 72 is shown, oriented with its longest side generallyperpendicular to the lengthwise-extension of the sheet holding suchpattern and thus generally perpendicular to the extended length of thefunctional element. In FIG. 5D, a trapezoidal slot perforation 74 isshown, oriented at a slant with respect to the lengthwise extension ofthe sheet holding such pattern. The pattern sheets in FIGS. 5A to 5D arerepresentative of the types of patterns that may be employed. Otheradvantageous patterns may be designed to meet specific requirements.Preferably, the patterns are cut through one outer layer of thefunctional stretch laminate, either while the layer is held in aplanarized and fixed position or prior to assembling such layer withinthe functional stretch laminate. Optionally, such patterns may be cutthrough both outer layers of the functional stretch laminate.

FIGS. 5E and 5F are perspective views of functional stretch laminateswherein portions of the functional elements loop out of one outer layerof the laminate. In FIG. 5E, two loops, 76 a and 76 b, are shownextending through an elongated slot-shaped perforation 74. In FIG. 5F,four loops, 78 a, 78 b, 78 c, and 78 d, are shown each extending throughan individual perforation hole.

Referring next to FIGS. 6A and 6B, the perforations 60 and 60′ in theouter layer create openings through which the functional elements may beexposed upon releasing tension and relaxing the laminate structure.Functional elements 5 and 5′ within the laminate form loops 65 and 65′along portions of the length of the laminate. The functional elements 5and 5′ are coextensive with stretch and recovery element 10. The stretchlaminate 55 is provided with perforations 60 and 60′ in one of thenonwoven layers. These perforations are separated by a distance P whichis defined for the laminate while under elongating tension. Any numberof perforations 60, 60′ may be present in one or both of the nonwovenlayers. Generally, the distance P, separating perforations, is fixedalong any portion of the total length of the laminate. The distance Pmay be tailored to provide access to one or more functional elements atchosen fixed intervals. Optionally, both nonwoven layers may containperforations 60 and 60′, which allow looping out of the functionalelements 5 and 5′ on opposing sides of the laminate. In FIGS. 6A and 6Bthe composite fabrics are shown in schematic representation in a relaxedstate under no elongating tension. The looping out portions 65 and 65′of the functional elements 5, 5′ extend a greater distance from thelaminate under no elongating tension.

The degree that looping out portions 65 and 65′ can project away from avia is at least, in part, a function of the bending modulus of thefunctional or conductive element. Conductive elements such as Siliconecoated wire, Rea wire, Beadlon wire, FEP wire, or copper ribbon withhigher bending modulus can dramatically protrude from the via as thelaminate structure is relaxed. In contrast, softer conductive elementswith a lower bending modulus, such as X-static, tend to remain in theplane of the non-woven, i.e., resting in the via for ease of access ortermination.

FIG. 7A is a perspective view of a functional stretch laminate 55 of theinvention comprised of two nonwoven fabrics, 35 and 35′, and having twofunctional elements, 5 and 5′, coextensive with stretch and recoveryelement (not shown in FIG. 7A) and including a folded over portion 100or z-fold at each end. The folded over portion 100 functions as a strainrelief, to help maintain the functional elements within the laminatestructure.

The folded over portion 100 also permits a connector means to be clampedabout the folded over portion. In FIG. 7B, an end portion of a laminateis represented in cross-section includes a clamping means comprising afirst portion 110 and a second portion 120. The first portion 110 of theclamping means is provided with at least a pair of threaded holes eachadapted to receive the threads of a bolt 130, which passes through thesecond portion of the clamping means 120 and engages the threads ofportion 110. In FIG. 7B, the two portions of the clamping means 120 and110, represented in cross-section, are completely engaged by means ofthe threaded bolts and provide a tight clamping of the folded overportion of laminate 55.

The invention is further illustrated in view of the Examples below.

EXAMPLES

The samples in these examples were made using a brand of spandexidentified as 1520 decitex Lycra® XA® (Lycra® is a registered trademarkof INVISTA S. à r. l., a private limited company of Luxembourg withoffices at 4123 East 37th Street North, Wichita, Kans. 67220, USA) and anonwoven fabric of polypropylene fibers (obtained from Perkins SalesInc., Edisto Island S.C., USA 29438), having a basis weight of 15 g/m².

The functional or conductive element in the structures of the Exampleswere: in Example 1, Xstatic® yarns (obtained from SAUQUOIT Industries,Inc., Scranton, Pa., USA); in Example 2: (1) 29 gauge copper strandedwire coated with silicone; (2) 29 gauge copper stranded wire coated witha hard, black-colored FEP coating; (3) “BEADALON” Professional Seriesbead stringing wire, a nylon coated, 49 strand wire 0.013″ or 0.33 mmavailable from BEADALON, West Chester, Pa., 19382; and (4) a goldcolored 90 micron wire and a black colored 70 micron wire, which areinsulated silver plated copper conductors (obtained from ElektroFeindraht, Escholzmatt, Switzerland) of diameters 0.040 mm-0.090 mm; inExample 3, single strand polyester and nylon insulated copper wire(obtained from Pelican Wire Company, Naples, Fla., USA) with sizesranging from 38-42 AWG; and in Example 4, copper ribbon conductorshaving a rectangular cross section, with a 0.003 inch thickness and0.0620 inch width (a product of Rea Magnet Wire, Inc., Fort Wayne, Ind.,USA; obtained from Nicomatic North America, One Ivybrook Blvd, 20,Warminster, Pa., USA 18974). The physical properties of some of theabove conductive elements were measured or obtained from each wiresupplier and are summarized in Table 1.

TABLE 1 INSTRON Break Wire Diameter Resistance (grams Source Color AWG(millimeters) in Ohms force) ¹Pelican red 42 0.064 2.3 85.30 ¹Pelicangreen 40 0.079 1.4 121.21 ¹Pelican blue 38 0.102 0.9 225.68 ²Elektro-gold 39 0.090 1.0 144.17 Feindraht ²Elektro- black 41 0.071 1.7 110.57Feindraht ²Elektro- violet 44 0.050 2.8 49.73 Feindraht ²Elektro- blue46 0.040 3.8 30.33 Feindraht ¹Pelican Wire Company, Inc. 6266 Taylor Rd.Naples, FL 34109-1839 ²Elektro-Feindraht AG 6182 Escholzmatt Switzerland

Each of the test samples was washed as described below and repeatedlystretched using the Zwick Textile Fatigue Testing Machine (530 I; 8position, after De Mattia). The Zwick testing machine is available fromZwick Testing Machines Ltd., Southern Avenue, Leominster, HerefordshireHR6 OQH, UK. The electrical resistance or conductivity was measured, inthe manner known to those skilled in the art of electrical measurement,before and after each Zwick textile fatigue test. The wash durabilitytesting method was comprised of a machine wash cycle with warm (40° C.)water and a cold rinse (room temperature water) using AmericanAssociation of Textile Chemists and Colorists (AATCC) WOB StandardPowder Detergent with a hanging to dryness phase at room temperature.

Example 1 Part A

In Example 1, Part A, a 5 cm wide functional stretch laminate wasprepared using the apparatus schematically represented in FIG. 1. Thestretch laminate had 3 conductive Xstatic® yarns (a conductive yarnobtained from SAUQUOIT Industries, Inc., PO Box 3807, 300 Palm Street,Scranton, Pa., 18505, USA, which was based on a 70 denier, 34 filamentnylon available from INVISTA S. à r. l (product ID number 70-XS-34×2 TEX5Z)) and 22 LYCRA® spandex threads. The spandex and the conductive yarnwere supplied from rolls to the apparatus illustrated in FIG. 1 and thespandex threads were placed substantially parallel and equidistant fromeach. The Xstatic® yarns were laid over the LYCRA® spandex in positions4, 11, and 18 of the 22 spandex threads, which were on a pitch of about2 millimeters. The spandex was stretched to not less than 100% andbonded between two layers of the nonwoven fabric with a hot meltadhesive. The two layers of nonwoven fabric were supplied by rolls tothe apparatus shown in FIG. 1 (see, for example, the rolls 33 and 33′)under sufficient tension to effectively planarize the two nonwovenfabrics. The conductive element was in its relaxed state under notension and was introduced into the structure by contact with thestretched spandex before the adhesive was introduced.

For all samples, the adhesive was melt blown onto the spandex justbefore contacting the bottom layer of nonwoven fabric. For all samples,a styrene/isoprene block copolymer-based adhesive, H-2766, was used(product of Bostik Findley Inc., Wawatosa, Wis., USA), at 86.4 g/min.The adhesive was applied at 149° C. The speed of the samples entering apair of nip rollers (substantially the same as schematically representedby nip rolls 50 in FIG. 1) was 300 ft/min (91.5 m/min), the nip rollpressure was 60 psi (414 kPascal). The top and bottom layers of nonwovenfabric and the intervening spandex and conductive filaments becameadhesively bonded by this process, followed by removal of the tension onthe spandex. Following the removal of the tension on the spandex, apuckered fabric was produced having a substantially uniform flat surfaceappearance due to small and substantially uniform puckers.

Table 2 contains the electrical resistance data for samples of thefunctional stretch laminate of Example 1, Part A. Wash testing of thesample showed no profound change in DC electrical resistance for eachindividual conductive element, other than a small increase to less twotimes the before washing resistance. The Zwick fatigue test of tenthousand (10,000) repeat cycles showed no failure of the individualconductive elements.

TABLE 2 Wash Testing (51 inch long sample with 3 conductors) Before WashAfter Wash Resistance Resistance Conductor (ohms) (ohms) conductor # 10.952K 1.520K conductor # 2 1.033K 1.634K conductor # 3 0.817K 1.574KZwick Test (two 6.5 inch samples folded & twisted into a figure-of-8)Resistance Resistance (ohms) (ohms) after Zwick before Test of 10,000Zwick Test cycles Sample 1 conductor # 1 0.116K 0.138K conductor # 20.107K 0.134K conductor # 3 0.130K 0.155K Sample 2 conductor # 1 0.135K0.156K conductor # 2 0.105K 0.135K conductor # 3 0.135K 0.202K

Example 1 Part B

Example 1, Part B, was carried out using Xstatic® yarns as theconductive element in the functional stretch laminate. Two samples weremade in Example 1, Part B precisely in the same process as thatdescribed for Example 1, Part A. In this Part B example, 12 LYCRA®spandex threads were used and Xstatic® yarns were inserted in positions2, 3, 4, 5, 8, 9, 10 and 11, thereby overlaying 8 of the 12 LYCRA®spandex threads respectively. The resulting functional stretch laminatewas about 2.5 cm in width. Two samples were prepared in the Part Btrials and a 15 inch long sample of each was measured for resistance, asbefore, and washed tested in the same manner. Each of the 8 conductorswas tested after 10 wash cycles.

As shown by Tables 3A and 3B, the resistance for each conductorincreased only slightly, and no conductive element was damaged by thewashing treatment. As a result, the functional stretch laminate producedin this way is sufficiently robust to endure normal laundry conditionsand still maintain its useful electrical conduction.

TABLE 3A Sample 1 Wash Test (15 inch sample) Conductor Resistance (ohms)Resistance (ohms) Identification before wash after 10 washings thread #1 243 360 thread # 2 226 273 thread # 3 204 235 thread # 4 237 323thread # 5 130 163 thread # 6 148 156 thread # 7 275 327 thread # 8 210281

TABLE 3B Sample 2 Wash Test (15 inch sample) Conductor Resistance beforeResistance after 10 Identification wash (ohms) wash (ohms) thread # 1207 284 thread # 2 208 317 thread # 3 150 282 thread # 4 159 299 thread# 5 233 328 thread # 6 205 290 thread # 7 178 275 thread # 8 230 392

Example 2

In Example 2, a 2.5 cm wide functional stretch laminate was prepared asin Example 1, except 19 LYCRA® spandex threads were placed substantiallyequidistant and parallel and, in four separate functional stretchlaminates, the following functional elements were placed alongside ofthe LYCRA® spandex threads in positions 2 and 10: (1) in the firstfunctional stretch laminate, 29 gauge copper stranded wire coated withsilicone; (2) in the second functional stretch laminate, 29 gauge copperstranded wire coated with a hard, black-colored FEP coating; (3) in thethird functional stretch laminate, “BEADALON” Professional Series beadstringing wire, a nylon coated, 49 strand wire 0.013″ or 0.33 mmavailable from BEADALON, West Chester, Pa., 19382; and (4) in the fourthfunctional stretch laminate, a gold colored 90 micron wire and a blackcolored 70 micron wire. Three samples of each functional stretchlaminate were prepared, each containing one of the four functionalelements (for a total of twelve samples). Each sample was tested usingthe Zwick fatigue tester for ten thousand (10,000) cycles. For thesamples using one of the first three functional elements, two six inchlong functional stretch laminates were folded at 75% stretch. Forsamples using the fourth functional element, two six and a half inchlong conducive stretch laminates were folded and twisted into a figureeight. The resistance of each conductive element was tested before andafter Zwick testing.

The results in Table 4 show that each of the samples prepared with thefirst three functional elements were able to endure the Zwick testprocedure. However, the samples prepared with the fourth functionalelement did not endure the Zwick test procedure (as a result of thewires breaking as opposed to destruction of the stretch laminateitself).

TABLE 4 Zwick Test Results Identification Resistance (ohms) (FunctionalResistance (ohms) after Zwick test of Sample Element) before Zwick test10,000 cycles Laminate #1 Silicone 1.0 0.7 coated copper wire Laminate#2 Silicone 1.0 0.7 coated copper wire Laminate #3 Silicone 1.0 0.6coated copper wire Laminate #4 FEP coated 1.0 0.5 copper wire Laminate#5 FEP coated 1.0 0.5 copper wire Laminate #6 FEP coated 0.8 0.5 copperwire Laminate #7 BEADALON 14.3 12.0 wire Laminate #8 BEADALON 13.4 11.7wire Laminate #9 BEADALON 13.4 11.6 wire Laminate #10 wire-gold & gold:2.0 no conductivity, black black: 3.9 wire broken Laminate #11 wire-gold& gold: 3.4 no conductivity, black black: 6.1 wire broken Laminate #12wire-gold & gold: 4.1 no conductivity, black black: 4.8 wire broken

Example 3

In Example 3, functional stretch laminates were prepared as inExample 1. The Example 3 functional stretch laminates had either 4 or 8conductive elements comprised of insulated silver-plated single strandcopper wires. These wires are described by their respective colors givenin Table 1. Where there were 4 conductive elements, they were introducedto the functional stretch laminate in positions 2, 5, 8, and 11 of the12 LYCRA® spandex yarns. Where there were 8 conductive elements, theywere introduced to the functional stretch laminate in positions 1, 3, 4,6, 7, 9, 10, and 12 of the 12 LYCRA® spandex yarns. The resultingfunctional stretch laminate was about 2.5 cm wide. After being subjectedto the wash test described for Example 1, the functional stretchlaminate samples were subjected to the electrical resistancemeasurements as described above. In addition, the functional stretchlaminate samples were subjected to electrical resistance measurementsbefore and during elongation to 30% over the relaxed length of thelaminate sample. Zwick fatigue test measurements were conducted as inthe previous examples.

Tables 5 through 9 below summarize the test and measurement data forExample 3.

TABLE 5 Sample 3A (8 conductors: red 42 Resistance (ohms) Resistance(ohms) AWG & green 40 AWG) before washing after 10 washings Red wire # 18.6 7.9 Green wire # 2 5.8 failed Green wire # 3 5.4 failed Red wire # 47.4 6.9 Red wire # 5 8.9 failed Green wire # 6 7.6 failed Green wire # 75.0 failed Red wire # 8 7.5 7.5

TABLE 6 Sample 3B (8 conductors: red 42 Resistance (ohms) Resistance(ohms) AWG & green 40 AWG) relaxed stretched 30% Red wire # 1 2.3 2.3Green wire # 2 1.6 1.6 Green wire # 3 1.8 1.8 Red wire # 4 2.4 2.4 Redwire # 5 2.5 2.5 Green wire # 6 1.6 1.6 Green wire # 7 1.7 1.7 Red wire# 8 2.5 2.5

TABLE 7 Sample 3C Resistance (ohms) Resistance (ohms) (blue 38 AWG)before washing after 10 washings Blue wire # 1 4.6 failed Blue wire # 25.3 2.9 Blue wire # 3 3.1 2.9 Blue wire # 4 4.8 3.0

TABLE 8 Sample 3D Resistance (ohms) Resistance (ohms) (blue 38 AWG)before washing after 10 washings Blue wire # 1 3.0 3.1 Blue wire # 2 4.03.0 Blue wire # 3 4.8 2.9 Blue wire # 4 3.1 failed

TABLE 9 Resistance (ohms) after Resistance (ohms) Sample 3C Zwick 3000after Zwick 6000 (blue 38 AWG) cycles cycles Blue wire # 1 1.3 Noconductivity, failed test Blue wire # 2 No conductivity, Noconductivity, failed test failed test Blue wire # 3 No conductivity, Noconductivity, failed test failed test Blue wire # 4 No conductivity, Noconductivity, failed test failed test

Example 4

In this example, a pair of uninsulated flat copper ribbons (measured incross section: 0.003 inch by 0.062 inch) were used as the conductiveelement. A single twisted pair of LYCRA® spandex yarns comprised of two1520 decitex Lycra® XA® threads was used as the stretch and recoveryelement. The Lycra® XA® was maintained in a draft of about 1.3 timeswhile the conductive elements were inserted, with their widest dimensionin the plane of the nonwoven fabrics, between the two nonwoven fabricsto form the functional stretch laminate. The process used for making thestretch laminate was otherwise substantially the same as that processused in previous examples. The resulting laminate was about 2.5 cm wideand the conductive elements about 1.5 cm apart, while the single twistedpair of LYCRA® spandex yarns was between the copper conductive elements.The laminate had a puckered appearance in the relaxed statecharacterized by a repeat length L of about 15 to 20 mm, as illustratedschematically in FIG. 4B.

Example 5

This example shows that the performance of a terminated laminatestructure can be improved by folding the laminate structure at leastonce back on itself in a fold, and preferably at least twice in az-fold, zig-zag or s-wrap configuration, and then securing the ends witha mechanical fastening system such as gluing, snapping, rivets,stitching, and/or staples, as shown, for example, in FIGS. 7A and 7B,which show a mechanical fastening system in the form of a clampingmeans.

The functional stretch laminates used for this example were each aboutone inch wide and eight inches long and otherwise made according to themethod of Example 2 wherein the following functional elements wereplaced alongside of the LYCRA® spandex threads in positions 2 and 10:(1) in the first functional stretch laminate, 29 gauge copper strandedwire coated with silicone; (2) in the second functional stretchlaminate, 29 gauge copper stranded wire coated with a hard,black-colored FEP coating; (3) in the third functional stretch laminate,“BEADALON” Professional Series bead stringing wire. A regular snap wasused as the mechanical fastening system.

The above laminates were tested to determine the amount of forcerequired to pull the functional elements from the laminate structure.The amount of force required to pull the functional elements from eachlaminate was determined by placing each laminate on an Instron pullforce test machine in a room at 70° F. (21.1° C.) and 65% relativehumidity. The instron pull force test machine was an Instron Model 5565equipped with the Merlin data collection software system (both theMerlin system and instrument hardware are available from InstronCorporation (Braintree, Mass.)). A one inch+/−0.05 inch wide (2.54cm+/−0.13 cm) and approximately 8 inch (20.32 cm) long sample of astretch nonwoven sheet was clamped in the jaws of the Instron machinewith a sample length set at 3.00 inches (7.62 cm). The sample wasprepared such that the length of the sample was aligned with thedirection of the spandex and/or functional element of the stretchnonwoven. The sample was elongated at a rate of six inches per minute(15.24 cm/min) until the sample broke into two portions and the maximumforce in grams at the break point was recorded.

As shown in Table 10, laminate structure ends that have been folded onthemselves and secured hold the functional elements more securely withinthe laminate structure. It can require between about 2 to 3 times theforce to pull the functional/conductive elements from the structure, ascompared to the force to pull standard unsecured conductive elements,which can be pulled from a glued laminate structure with a lowerpullingforce.

TABLE 10 Pull Test Results (unit lbs of force required to pull or breakfunctional materials) Snapped Glued Standard S-Wrap S-Wrap SampleConfiguration Configuration Configuration Laminate #1 0.54 6.49 7.56(silicone coated copper wire) Laminate #2 4.6 4.44 8.67 (silicone coatedcopper wire) Laminate #3 3.09 7.38 10.95 (FEP coated copper wire)Laminate #4 5.42 9.79 6.03 (FEP coated copper wire) Laminate #5 6.6214.61 20.67 (BEADALON wire) Laminate #6 8.09 16.65 13.66 (BEADALON wire)

Example 6

This example provides a stretch laminate that is substantially identicalto that of Example 4, except it has at least one modified outer layer.As in previous examples, copper-based conductive elements, wires,ribbons, and/or metallic plated yarns can be introduced between twonon-woven layers along with a spandex yarn. The spandex is stretched toat least 100% and is bonded between two layers of the nonwoven fabricwith a hot melt adhesive. The two layers of nonwoven fabric are, as inExample 1, supplied on rolls (such as 33 and 33′ in FIG. 1) undersufficient tension to effectively planarize the two nonwoven fabrics.The conductive elements (copper ribbons) are in a relaxed state under notension. The adhesive is melt blown onto the spandex just beforecontacting the bottom layer of nonwoven fabric.

In this example, perforations are provided in one of the outer layers atintervals along a path substantially co-linear with the one of theconductive elements, e.g. co-linear with at least one of the two copperribbons. These perforations in the outer (nonwoven) layer are punctuatedalong the length of the nonwoven material. Such perforations are alsoknown in the electrical and electronic arts as “vias” (vias areconstrued here to mean a through-passage communicating from one surfaceto another and through which a wire or functional element passes, sothat the wire is underneath such via).

As shown in FIG. 5, the perforations can, for example, be geometricshaped rectangles or circular cross-sectionally shaped holes obtained bya “hole-punching” means. Any cross-sectional shape is generally suitableand is readily provided by a hole punch die having the desired shape.Hole-punching means can, for example, include a hand held device, whichproduces a single hole, and a 3-hole paper punch used to make 3-ringbinder holes in paper. In general, such hole-punching means are used ina step-and-repeat fashion to make a series of holes of a fixed spacinginterval in the non-woven.

Alternatively, the non-woven sheet may be fed through a dedicated holepunching apparatus capable of hole punching on a fixed spacing interval(“a fixed pitch”, P, as shown in FIG. 6A) or on a randomly spacedinterval selected by the operator. Alternately, the non-woven sheet maybe scored. The non-woven sheet, so perforated or scored, can be wound upin a conventional manner to then be mounted in an apparatus (such asthat shown in FIG. 1, in either or both of positions denoted as 33 or33′). In an alternative embodiment, vias can be cut in any shapedirectly into multiple layer depths of an un-wound roll. The perforatednon-woven can then used to form a functional stretch laminate,substantially as represented schematically in FIG. 6A, and in therelaxed form in FIG. 6B.

Nothing in this specification should be considered as limiting the scopeof the present invention. All examples presented are representative andnon-limiting. The above described embodiments of the invention may bemodified or varied, and elements added or omitted, without departingfrom the invention, as appreciated by persons skilled in the art inlight of the above teachings. It is therefore to be understood that theinvention is to be measured by the scope of the claims, and may bepracticed in alternative manners to those which have been specificallydescribed in the specification.

1. A functional stretch laminate, comprising: (a) a first outer layer ofa fabric or film defining an inner surface and an outer surface and alength, and defining two or more perforations therethrough, with eachperforation defining a hole opening with a maximum outer dimension; (b)a second outer layer of a fabric or film, said second layer defining aninner surface and an outer surface; (c) two or more threadlines ofstretch and recovery elements extending along at least a portion of thelength of the first outer layer; (d) two or more wires, yarns or strandsof functional elements substantially parallel to or co-extending withthe stretch and recovery elements, said functional elements having athreadline length and having an outer diameter or maximum outer widthless than the maximum outer dimension of a corresponding perforationhole opening, with the stretch and recovery elements and functionalelements sandwiched between the inner surfaces of the outer layers; and(e) at least one adhesive composition for bonding the stretch andrecovery elements and the functional elements between the inner surfacesof the outer layers; wherein portions of one functional element areexposed to an environment outside of the laminate through the two ormore perforations, and wherein a puckered appearance results when thestretch and recovery elements are in a relaxed or unstretched state. 2.The functional stretch laminate of claim 1, wherein when the stretch andrecovery elements are in a relaxed or unstretched state, at least oneportion of at least one functional element loops beyond the outersurface of the first outer layer through at least one of theperforations in a direction substantially perpendicular to a planedefined by the outer surface of the first outer layer, and at least oneother portion of at least one functional element loops beyond the outersurface of the first outer layer through at least one other of theperforations in a direction substantially perpendicular to a planedefined by the outer surface of the first outer layer.
 3. The functionalstretch laminate of claim 1, wherein the functional elements are presentin an amount from 1 to 20 per inch of width of the laminate.
 4. Thefunctional stretch laminate of claim 1, wherein the perforations areformed in the first outer layer at predetermined intervals along thelength.
 5. The functional stretch laminate of claim 1, wherein theperforations are formed in the first outer layer at predeterminedintervals along the length before the stretch and recovery elements andfunctional elements are bonded between the first outer layer and secondouter layer.
 6. The functional stretch laminate of claim 1, wherein theperforations have a shape selected from the group consisting of a hole,a slit, a slot, and combinations thereof.
 7. The functional stretchlaminate of claim 2, wherein at least two functional elements loopbeyond the outer surface of the first outer layer through the sameperforation.
 8. The functional stretch laminate of claim 1, wherein theretractive force of the laminate is at least 0.22 lb/in (38.9 g/cm) whenthe laminate is stretched to 150% of its original length.
 9. Thefunctional stretch laminate of claim 1, wherein the stretch and recoveryelements comprise spandex.
 10. The functional stretch laminate of claim1, wherein the functional elements are selected from the groupconsisting of: insulated single and multi-stranded metallic wires,non-insulated single and multi-stranded metallic wires, metallic coatedpolymeric fibers, inherently conductive polymer fibers, plastic opticalfiber, silica glass optical fibers, metallic coated films, andcombinations thereof.
 11. The functional stretch laminate of claim 1,wherein at least one functional element comprises at least one materialhaving functional properties that is intermingled, twisted, core spun,or covered together with: (i) at least one other material havingfunctional properties, or (ii) a material having stretch and recoveryproperties.
 12. The functional stretch laminate of claim 11, wherein thematerial having stretch and recovery properties comprises spandex, andthe material having functional properties is selected from the groupconsisting of metal wire, an electrically or optically functionalcomposite yarn that comprises an elastic member surrounded by at leastone functional covering filament, an electrically conductive elastomericcomposition that exhibits variable resistance, and silver plated textilenylon filament.
 13. The functional stretch laminate of claim 1, whereinthe fabric or film outer layers are selected from the group consistingof nonwoven fabric, woven fabric, knit fabric, paper, and polymer film.14. The functional stretch laminate of claim 1, wherein a distal end ofthe functional stretch laminate is folded back onto itself at least onetime and such folded end is fastened to the outer surface of one outerlayer.
 15. The functional stretch laminate of claim 14, wherein thefolded end is fastened by a mechanical fastening mechanism selected fromthe group consisting of gluing, riveting, snapping, stitching, stapling,welding, and encasing.
 16. The functional stretch laminate of claim 1,wherein the laminate is adaptable for attachment to at least oneconnector, wherein said connector is adaptable for connecting thefunctional element in the laminate to a source selected from the groupconsisting of electricity and radiation.
 17. A method for preparing afunctional stretch laminate, comprising: providing a length of a firstpiece of inextensible material having an inner surface and an outersurface and a length, and defining two or more perforationstherethrough, with each perforation defining a hole opening with amaximum outer dimension; providing a second piece of inextensiblematerial having an inner surface and an outer surface, extending two ormore threadlines of stretch and recovery elements to at least 50% oftheir undeformed recoverable extension limit and fixing said stretch andrecovery elements along at least a substantial portion of the length ofthe first piece of inextensible material, extending two or more wires,yarns or strands of functional elements coextensively with the stretchand recovery elements and fixing said functional elements along at leasta substantial portion of the length of the first piece of inextensiblematerial, said functional elements having a threadline length and havingan outer diameter or maximum outer width less than the maximum outerdimension of a corresponding perforation hole opening, securing theextended stretch and recovery elements and the functional elements tothe inner surface of said first piece of inextensible material along asubstantial portion of the length thereof; bonding the stretch andrecovery elements and the functional elements between the inner surfaceof said first piece of inextensible material and the inner surface ofthe second piece of inextensible material to form the functional stretchlaminate; and relaxing the extended length of said stretch and recoveryelements substantially and allowing the functional stretch laminate topucker, such that portions of the functional elements are exposed to anenvironment outside of the laminate through the holes provided in thefirst piece of inextensible material.
 18. The method of claim 17,wherein the stretch and recovery elements and the functional elementsare substantially parallel when extended.
 19. The method of claim 17,wherein the stretch and recovery elements comprise spandex.
 20. Themethod of claim 17, wherein the functional elements are selected fromthe group consisting of: insulated single and multi-stranded metallicwires, noninsulated single and multi-stranded metallic wires, metalliccoated polymeric fibers, inherently conductive polymer fibers, plasticoptical fiber, silica glass optical fibers, and metallic coated films.21. The method of claim 17, wherein the inextensible material is afabric or film selected from the group consisting of nonwoven fabric,woven fabric, knit fabric, paper, and polymer film.
 22. The method ofclaim 17, further comprising perforating the first piece of inextensiblematerial to form the perforations before securing the extended stretchand recovery elements and the functional elements to the inner surfaceof the first piece of inextensible material.
 23. The method of claim 22,wherein the hole opening is selected from the group consisting of ahole, a slit or a slot.
 24. The method of claim 22, further comprisingperforating the second piece of inextensible material to form one ormore hole openings before securing the extended stretch and recoveryelements and the functional elements to the second piece of inextensiblematerial.
 25. The method of claim 17, further comprising the steps of:(i) folding a distal end of the functional stretch laminate back ontoitself at least one time; and (ii) fastening such folded end to theouter surface of one piece of inextensible material.
 26. The method ofclaim 25, wherein fastening is by a mechanical fastening mechanismselected from the group consisting of gluing, riveting, snapping,stitching, stapling, welding, and encasing.
 27. The method of claim 17,further comprising the step of attaching at least one connector to thefunctional stretch laminate, wherein said connector is adaptable forconnecting the at least one of the functional elements in the laminateto a source selected from the group consisting of: electricity andradiation.
 28. A garment or wearable incorporating the functionalstretch laminate of claim
 1. 29. The functional stretch laminate ofclaim 1, wherein the second outer layer defines two or more perforationstherethrough, and wherein at least a portion of another one of the twoor more functional elements is exposed to an environment outside of thelaminate through the two or more perforations of the second outer layer.